AWWA C 204 Mortar Lined MS Pipe
AWWA C 204 Mortar Lined MS Pipe
PART 1 - GENERAL
1.1
1.2
REFERENCE SPECIFICATIONS
A.
1.3
The WORK of this Section includes providing mortar-lined and mortarcoated steel pipe, including fittings and specials, complete in place.
AWWA
AWWA
C200
C205
3.
4.
5.
AWWA
AWWA
AWWA
C206
C207
C208
6.
AWWA
C602
7.
AWWA
M11
SUBMITTALS
A.
Shop drawings
a.
b.
Joint and fitting wall construction details which indicate the type
and thickness of cylinder; the position, type, size, and area of
reinforcement; manufacturing tolerances; and all other pertinent
information required for the manufacture of the product.
c.
Joint details shall be submitted where deep bell or butt strap joints
are required for control of temperature stresses.
d.
2.
B.
f.
g.
Design Calculations
a.
b.
Test Reports
1.
1.4
Certificates
1.
C.
e.
b.
c.
d.
Upon request by the DISTRICT, mill test reports on each sheet from
which steel is rolled will be submitted.
INSPECTION
A.
Factory Inspection
1.
2.
1.5
1.6
WELDING
A.
All welding procedures used to fabricate pipe shall be prequalified under the
provisions of AWS D1.1.
B.
Welding procedures shall be required for, but not necessarily limited to,
longitudinal and girth or spiral welds for pipe cylinders, spigot and bell ring
attachments, reinforcing plates and ring flange welds, and plates for lug
connections.
C.
All welding shall be done by skilled welders, welding operators, and tackers
who have had adequate experience in the methods and materials to be used.
D.
E.
The CONTRACTOR shall furnish all material and bear the expense of
qualifying welders.
TESTING
A.
Except as modified herein, all materials used in the manufacture of the pipe
shall be tested in accordance with the requirements of AWWA C200 and
C205, as applicable.
1.
2.
b.
welds which may be revealed by the test shall be chipped out and
rewelded and the special retested.
b.
B.
C.
D.
All expenses incurred in making samples for certification of tests shall be
borne by the CONTRACTOR.
PART 2 - PRODUCTS
2.1
GENERAL
A.
Mortar lined and coated steel pipe shall conform to AWWA C200 and C205,
subject to the following supplemental requirements. The pipe shall be of the
diameter and class shown, shall be furnished complete with rubber gaskets or
welded joints, as indicated in the Contract Documents, and all specials and
bends shall be provided as required for a complete piping system.
B.
Specials are defined as fittings, closure pieces, bends, reducers, wyes, tees,
crosses, outlets, manifolds, and other steel plate specials, wherever located,
and all piping above ground or in structures.
C.
Dimensions of fabricated steel pipe fittings shall comply with AWWA C208.
D.
Pipe 14 inches in diameter and larger, the inside diameter after lining shall
not be less than the nominal diameter specified or shown.
E.
F.
The pipe lining shall have smooth dense interior surfaces and shall be free
from fractures, excessive interior surface crazing and roughness.
G.
2.2
H.
The CONTRACTOR shall be fully liable for the cost of replacement or repair
of pipe and specials which are damaged.
I.
The CONTRACTOR shall legibly mark all pipes and specials in accordance
with the laying schedule and marking diagram. Each pipe shall be numbered
in sequence and said number shall appear on the laying schedule and
marking diagram in its proper location for installation.
J.
All special pipe sections and fittings shall be marked at each end indicating
the top. The word top shall be painted or marked on the outside top spigot
end of each pipe section.
STRUTTING
A.
2.3
2.
3.
4.
General
1.
The pipe shall be steel pipe, mortar-lined and mortar-coated, with rubber
gasketed or field welded joints as shown. The pipe shall consist of steel
cylinder, either shop-lined or lined-in-place with portland cementmortar with an exterior coating of cement mortar.
2.
3.
The pipe shall be of the diameter and indicated pressure class. The
minimum steel cylinder thickness for each pipe size shall be as indicated.
4.
Maximum pipe lengths for laying shall be 40 feet with shorter lengths
provided as required.
B.
T = Pw D/2
Y/St
Where:
D.
T =
D =
Pw =
Pt =
Y =
Sw =
St =
b.
T = Pt D/2
Y/Sw
Minimum Cylinder
Thickness (in.)
6 - 30
36
42
48
54
E.
0.135
0.150
0.175
0.200
0.225
DKWr3
EI + 0.0614 Er3
Where:
K =
W=
r =
EI =
E =
Note 1:
Note 2:
Note 3:
Trench Condition:
Wd = CdwBd2
Where:
Wd =
Cd
Load coefficient
Ku =
0.13
Bd
Wc
F.
2.4
Cc
Load coefficient
Ku
0.13
Bc
rsd
Settlement ratio
Projection ratio
If the calculated deflection, Deflx, exceeds 0.015 times the nominal diameter,
the composite pipe section shall be thickened or the quality of pipe zone
backfill shall be improved to achieve a higher soil modulus.
DESIGN SPECIALS
A.
T = Pw D/2
Y/Sw
Where:
b.
T = Pt D/2
Y/St
B.
In no case shall the design stress at design working pressure (Y/Sw) for
mortar-coated steel pipe exceed 16,500 psi or 22,000 psi at design transient
pressure (Y/St), nor shall plate thickness be less than the thickness of adjacent
mainline pipe or the following:
C.
2.5
2.4
Nominal Pipe
Diameter (in.)
Pipe Manifolds
Piping Above Ground
Piping in Structures
24 and under
25 to 48
over 48
3/16 - inch
1/4 - inch
5/16 - inch
Elbows
Bends
Reducers
10 - ga.
1/4 - inch
5/16 - inch
MATERIALS
A.
B.
All steel used for the fabrication of pipe shall have a maximum carbon
content of 0.25 percent, a maximum sulfur content of 0.015 percent, and shall
have a minimum elongation of 22 percent in a 2-inch gauge length.
C.
All steel used in fabricating pipe which exceeds 1/2-inch in thickness shall be
tested for notch toughness using the Charpy V-Notch test in accordance with
ASTM A370. The steel shall withstand a minimum impact of 25 ft. lb. at a
temperature of 30 degrees F.
D.
E.
JOINT DESIGN
A.
GENERAL
1.
The standard field joint for steel pipe shall be either a single-welded lap
joint or a rubber-gasketed joint for all pipe sizes up to and including 54inch diameter and shall be single-welded lap joint for pipe sizes above
60-inch diameter. Double welded joints with air taps for air pressure
testing shall be provided where shown.
2.
3.
Butt-strap joints shall be used only where required for closures or where
shown, or approved by the DISTRICT.
B.
C.
4.
The joints furnished shall have the same or higher pressure rating as the
abutting pipe.
5.
6.
7.
For field welded joints, design stresses shall not exceed 50 percent of the
indicated minimum yield strength of the grade of steel utilized, or 16,500
psi, whichever is less, for the part being examined when longitudinal
thrust is assumed to be uniformly distributed around the circumference
of the joint. At the CONTRACTORs option, the steel cylinder area may
be progressively reduced from the point of maximum thrust to the end
of the restrained length.
Lap Joints
1.
2.
The method used to form, shape and size bell ends shall be such that the
physical properties of the steel are not substantially altered. Unless
otherwise approved by the DISTRICT, bell ends shall be formed by an
expanding press or by being moved axially over a die in such a manner
as to stretch the steel plate beyond its elastic limit to form a truly round
bell of suitable diameter and shape. No process will be permitted in
which the bell is formed by rolling. Faying surfaces of the bell shall be
essentially parallel, but in no case shall the bell slope vary more than 2
degrees from the longitudinal axis of the pipe.
2.
The method used to form, shape and size bell ends shall be such that the
physical properties of the steel are not substantially altered.
2.7
3.
4.
5.
Faying surfaces of the bell and spigot shall be essentially parallel, but in
no case shall the bell slope vary more than 2 degrees from the
longitudinal axis of the pipe.
6.
Actual yield strength of the steel used in the spigot rolling operation (i.e.
yield strength values in mill certifications and subsequent destructive
test results) shall be limited to 50,000 psi.
7.
For bell-and-spigot ends with rubber gaskets, the clearance between the
bells and spigots shall be such that when combined with the gasket
groove configuration and the gasket itself, will provide watertight joints
under all operating conditions when properly installed.
8.
Full and complete information regarding location, type, size, and extent
of all welds shall be shown on the shop drawings. The shop drawings
shall distinguish between shop and field welds. Shop drawings shall
indicate by welding symbols or sketches the details of the welded joints,
and the preparation of parent metal required to make them. Joints or
groups of joints in which welding sequence or technique are especially
important shall be carefully controlled to minimize shrinkage stresses
and distortion.
General
1.
2.
3.
During the lining operation and thereafter, the pipe shall be maintained
in a round condition by suitable bracing or strutting.
4.
The lining machine shall be of a type that has been used successfully for
similar work.
5.
B.
C.
The pipe shall be left bare where field joints occur as indicated. Ends of the
linings shall be left square and uniform. Feathered or uneven edges will not
be permitted.
D.
E.
Cement-mortar for patching shall be the same materials as the mortar for
machine lining, except that a finer grading of sand and mortar richer in
cement shall be used when field inspection indicates that such mix will
improve the finished lining of the pipe.
F.
For all pipe and fittings with plant-applied cement-mortar linings, the pipe
manufacturer shall provide a polyethylene or other suitable bulkhead on the
ends of the pipe and on all special openings to prevent drying out of the
lining. All bulkheads shall be substantial enough to remain intact during
shipping and storage until the pipe is installed.
G.
2.8
b.
c.
d.
The exterior surfaces of pipe which will be exposed to the atmosphere inside
structures or above ground shall be thoroughly cleaned and then given a
shop coat of rust-inhibitive primer and a finish coat conforming to the
requirements of Section 04000.
B.
2.9
All pipe for buried service, including bumped heads, shall be coated with a 1inch minimum thickness of reinforced cement-mortar coating.
1.
2.
3.
The welded wire fabric shall be securely fastened to the pipe with
welded clips or strips of steel.
4.
FABRICATION OF SPECIALS
A.
General
1.
2.
3.
Specials and fittings shall be equal in pressure design strength and shall
have the same lining and coating as the adjoining pipe.
4.
B.
Fittings may be fabricated from pipe that has been mechanically lined or
coated.
C.
Access manholes with covers shall be as indicated. All threaded outlets shall
be forged steel suitable for 3000 psi service.
D.
E.
F.
G.
H.
I.
J.
Lining
1.
K.
Coating
1.
L.
Specials and fittings that cannot be mechanically lined and coated shall be
lined and coated by hand-application, using the same materials as are used
for the pipe and in accordance with the applicable AWWA C602 Standards.
Coating and lining applied in this manner shall provide protection equal to
that indicated for the pipe.
M.
Areas of lining that have been damaged by such fabrication shall be repaired
by hand-applications in accordance with applicable AWWA C602 Standards.
PART 3 - EXECUTION
3.1
INSTALLATION OF PIPE
A.
Immediately before placing each section of pipe in final position for jointing,
the bedding for the pipe shall be checked for firmness and uniformity of
surface to support the pipe for its full length.
B.
When the pipe is being laid, it shall be turned and placed where possible, so
that any slightly damaged portion will be on top. The damaged area shall be
repaired for the protection of any exposed steel.
C.
All damaged areas along the pipe shall be repaired using materials and
methods acceptable to the DISTRICT.
D.
E.
The maximum total allowable angle for beveled joints shall be 5 degrees per
pipe joint.
F.
The maximum allowable angle for pulled joints shall be in accordance with
the manufacturers recommendations or the angle which results from a 3/4
inch pull out from normal joint closure, whichever is less.
G.
All horizontal deflections or fabricated angles shall fall on the alignment. [In
congested city streets or at other locations where underground obstructions
may be encountered, the chord produced by deflecting the pipe shall be no
further than 6 inches from the alignment indicated.]
H.
All vertical deflections shall fall on the alignment and at locations adjacent to
underground obstructions, points of minimum earth cover, and pipeline
outlets and structures. The pipe angle points shall match the angle points
indicated.
I.
For pipe wall thicknesses of 3/8-inch or less, the maximum radial offset
(misalignment) for submerged arc and gas metal arc welded pipe shall be
0.1875 times the wall thickness or 1/16-inch, whichever is larger.
J.
For pipe wall thickness greater than 3/8-inch, the maximum radial offset
shall be 0.1875 times the wall thickness or 5/32-inch, whichever is smaller.
K.
L.
M.
For pipe 24 inches in diameter and larger, pipe struts shall be left in place
until backfilling operations have been completed.
3.2
3.3
N.
O.
The openings of all pipe and specials where the pipe and specials have been
cement-mortar lined in the shop shall be protected with suitable bulkheads to
maintain a moist atmosphere and to prevent unauthorized access by persons,
animals, water or any undesirable substance. The bulkheads shall be so
designed to prevent drying out of the interior of the pipe.
The
CONTRACTOR shall introduce water into the pipe to keep the mortar moist
where moisture has been lost due to damaged bulkheads.
Immediately before jointing pipe, the spigot end of the pipe shall be
thoroughly cleaned, and a clean rubber gasket lubricated with a NSF
approved vegetable-based lubricant shall be placed in the spigot groove.
B.
C.
The bell of the pipe already in place shall be carefully cleaned and lubricated
with a NSF approved vegetable-based lubricant. The spigot of the pipe
section shall then be inserted into the bell of the previously laid joint and
telescoped into its proper position.
D.
Tilting of the pipe to insert the spigot into the bell will not be permitted.
E.
After the pipe units have been joined, a feeler gauge shall be inserted into
the recess and moved around the periphery of the joint to detect any
irregularity in the position of the rubber gasket. If the gasket cannot be felt
all around, the joint shall be disassembled. If the gasket is undamaged, as
determined by the DISTRICT, it may be reused, but only after the bell ring
and gasket have been relubricated.
WELDED JOINTS
A.
General
1.
2.
3.
4.
Unless double fillet welds are indicated, field welded lap joints may, at
the CONTRACTORs option, be made on either the inside or the outside
of the pipe.
5.
6.
The pipe ends shall be cut straight on joints where butt straps are used
for realignment, adjustment, or deflection, and fillet welds shall be made
as indicated.
7.
After the pipe and pipe joint are properly positioned in the trench, the
length of pipe between joints shall be backfilled to at least 1 foot above
the top of the pipe. Care shall be exercised during the initial backfilling
to prevent movement of the pipe and to prevent any backfill material
from being deposited on the joint.
8.
Prior to the beginning of the welding procedure, any tack welds used to
position the pipe during laying shall be removed. Any annular space
between the faying surfaces of the bell and spigot shall be equally
distributed around the circumference of the joint by shimming, jacking,
or other suitable means. The weld shall then be made in accordance with
AWWA C206. Where more than one pass is required, each pass except
the first and final one shall be peened to relieve shrinkage stresses; and
all dirt, slag, and flux shall be removed before the succeeding bead is
applied.
9.
10. Following tests of the joint, the exterior joint spaces shall be coated in
accordance with these specifications after which backfilling may be
completed.
3.4
The interior and exterior joint recesses shall be thoroughly wiped clean and
all water, loose scale, dirt and other foreign material shall be removed from
the inside surface of the pipe.
B.
The cement for joint grout and mortar shall be portland cement acceptable
under ASTM C150 and shall be of the same type used for the pipe coating.
C.
After the pipe has been laid and after sufficient backfill has been placed
between the joints to hold the pipe securely in place, the outside annular
space between pipe sections shall be completely filled with grout formed by
the use of polyethylene foam-lined fabric bands.
D.
The grout shall be composed of one part cement to not more than 2 parts
sand, thoroughly mixed with water to a consistency of thick cream.
E.
The grout space prior to filling shall be flushed with water so that the surface
of the joint to be in contact with the grout will be thoroughly moistened
when the grout is poured.
F.
The joint shall be filled with grout by pouring from one side only, and shall
be rodded with a wire or other flexible rod or vibrated so that the grout
completely fills the joint recess by moving down one side of the pipe, around
the bottom of the pipe and up the opposite side. Pouring and rodding the
grout shall be continued to allow completion of the filling of the entire joint
recess in one operation.
G.
Grouting of the outside joint spaces shall be kept as close behind the laying of
the pipe as possible except that in no case shall grouting be closer than 3
joints of the pipe being laid.
H.
I.
1.
2.
The foam plastic shall be 100 percent closed cell, chemically inert,
insoluble in water and resistant to acids, alkali and solvents.
3.
The fabric backing shall be cut and sewn into 9-inch wide strips with
slots for the steel strapping on the outer edges.
4.
The polyethylene foam shall be cut into strips 6 inches wide and slit to a
thickness of 1/4-inch which will expose a hollow or open cell surface on
one side.
5.
The foam liner shall be attached to the fabric backing with the open or
hollow cells facing toward the pipe.
6.
The foam strip shall cover the full interior circumference of the grout
band with sufficient length to permit an 8-inch overlap of the foam at or
near the top of the pipe joint.
7.
8.
The polyethylene foam-lined grout band shall be centered over the joint
space with approximately equal widths extending over each pipe end and
securely attached to the pipe with steel straps. After filling the exterior joint
space with cement grout, the flaps shall be closed and overlapped in a
manner that fully encloses the grout with polyethylene foam. The grout
band shall remain in position on the pipe joint.
J.
Joint Lining
1.
After the backfill has been completed to final grade, the interior joint
recess shall be filled with mortar of stiff consistency mixed in
proportions of one part cement to 2 parts sand.
2.
The mortar shall be tightly packed into the joint recess and troweled
flush with the interior surface, and all excess shall be removed.
3.
4.
For pipe smaller than 24 inches in diameter, before the spigot is inserted
into the bell, the bell shall be daubed with mortar containing one part
cement to 2 parts sand. The spigot end then shall be forced to the bottom
of the bell and excess mortar on the inside of the joint shall be swabbed
out.
K.
The lining machine shall be of a type that has been used successfully for a
similar size of pipe. No ball (rabbit) shall be used. These joints shall be
video taped by the CONTRACTOR or hand holes shall be provided at each
joint, all at no additional cost to the DISTRICT.
L.
M.
N.
O.
Defective areas encompassing the full diameter of the pipe shall be replaced
by machine wherever the length measured along the pipe centerline is
greater than 5 feet; otherwise defective areas may be replaced by hand.
END OF SECTION